Standard Operating Procedure

Title: Environmental, Health and Safety – Risk Management

___________________________________________________________________________________________________________

Department Environmental, Health and Safety Document no EHS-010

Prepared by: Date: Supersedes:

Checked by: Date: Date Issued:

Approved by: Date: Review Date:

Document Owner
EHS Manager

Affected Parties
All Site colleagues

Purpose
The purpose of this SOP is to:
 Describe the risk management process of identifying EHS hazards, assessing risk, designing
appropriate controls and reviewing the controls.
 Describe the steps to take and the tool that shall be used to undertake preliminary risk assessments
(PRA).
 Outline the procedure for using the DR system for reporting EHS hazards that cannot be immediately
and simply resolved by the observer.

Scope
A risk assessment approach should be used for the following processes and situations:
 Prior to conducting any maintenance or installation work
 In the design of new plant, equipment and processes
 Prior to making changes to processes and equipment
 During EHS workplace inspections
 When conducting safety audits of new plant and equipment
 Organising job rotation / changes to job design
 Housekeeping audits
 Post incident / accident analysis
 Prior to purchasing new plant, equipment and chemical substances.
The EHS DR system is used to ensure that all corrective actions arising from incidents, EHS hazard
identification, EHS audits (Project, operational, EHS inspections) are documented, risk rated and tracked to
ensure timely and effective risk treatment implementation.

EHS Team: Leading EHS PRA’s and provides advise on EHS issues
Monitors progress of EHS deviations through the DR system.
All Employees: Are required to report hazards, incidents and accidents immediately to their line
manager and the EHS Team by use of the EHS Incident notification Form. If the
hazard cannot be addressed immediately, employees are required to raise a EHS
DR (DR2 see SOP QMS-035).
Area and Line Are responsible for managing hazards in their area of responsibility.

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Standard Operating Procedure
Title: Environmental, Health and Safety – Risk Management
___________________________________________________________________________________________________________
1.1. It is important to consider hazards, which may arise in all situations including:
 Transport
 Installation of plant/equipment
 Commissioning of plant /equipment
 Normal operation
 Cleaning and line clearance
 Set up / change over / loading consumables / waste handling
 Maintenance
 Emergency / abnormal conditions
 Following an accident or incident

1.2. Form-445 shall be used by the EHS Committee to identify potential hazards in work area
inspected.

1.3. The EHS Requirements specification includes a checklist for identifying hazards in new plant
and equipment.

1.4. Potential hazards and control measures associated with maintenance, installation and
process changes must be included in Change Control forms.

1.5. When reporting a EHS hazard, details of the hazard must be recorded in the Header Screen
of the EHS DR (See SOP QMS-035).

1.6. The identification of hazards must be comprehensive, systematic and should consider the
following:

The work environment: The work organisation:
- Lighting - Work flow
- Job and task design
- Noise levels
- Access / egress and - Job rotation
layout - Rate of work
- Floors / surfaces - Shift arrangements
- Use of PPE
- Competency of people using
the plant
- Carrying loads over distances
- Safe working procedures.
The plant, equipment, tools or
substances used:
- Exposure to Toxic
chemicals/gases
- Noisy machinery
- Generation of hazardous
conditions due to pressurised
content, electricity, radiation
friction, vibration, fire, explosion,
temperature, moisture, vapour,
gases, dust, ice, hot or cold parts.
- Control systems including
guarding.
- Stability
- Material used for construction.
- Tools and accessories
- Task appropriateness for plant.

2. Assess the risk

Considerations:

2.1. Risk assessment involves analysing all of the risks associated with hazards and evaluating
them to determine steps required for risk control and setting priorities.

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Standard Operating Procedure
Title: Environmental, Health and Safety – Risk Management
___________________________________________________________________________________________________________
 Introduction of new plant/equipment/processes/tasks
 Changes to plant/equipment/processes/tasks where a potential EHS impact has been identified
 Post incidents.
The EHS PRA shall be done with members from EHS committee, representatives from Project
Engineering and Electrical Engineering, and one or two representatives from the processes/areas
being assessed. An EHS Committee representative should also be invited to attend.

The different steps in the PRA are:

3.1. Undertaking Preliminary Risk Assessment - PRA.

Every potential hazard identified during the PRA, needs to be assigned a risk rating with the
use of the Risk Analysis Matrix under 2.3. A raw risk rating shall be initially be assigned,
assuming that there is no control treatment in place and a revised rating assigned after
considering any existing control treatments e.g. machine hazards pre-guarding and with
current guards in place. The aim is to assess the effectiveness of all existing control
treatments. Where it is identified that there are ineffective control treatments in place, an
EHS DR shall be raised and corrective actions assigned.

3.2. Document findings on the EHS Risk Profile Summary

All potential hazards and their risk rating for an area/process shall be summarised using
Form-380. This Summary shall be revised when there are changes made to the control
treatments or the profile of the potential hazards changes. The EHS Risk Profile Summary
shall be kept in the area and used to educate new staff, support periodic training and used
as a reference point when reviewing the “EHS Statement” in SOP’s particular to the area or
tasks. The EHS Team have the responsibility for updating the EHS Risk Profile Summary.
The Area manager is the owner of the EHS Risk Profile Summary for the corresponding
area.

3.3. Communicate Findings

The EHS Risk Profile Summary shall be kept in the area and the Area/line manager shall
communicate findings to all personnel, particularly any new staff.
PRA documentation and copies of the EHS Risk Profile Summary shall be accessible in the
area manager’s office.

3.4. Review
The Summary EHS Risk Profile will be reviewed by the Area manager, together with the
EHS committee, on an annual basis or when there are changes to the process/area that
have an impact on the SHE profile. The Area manager shall be responsible for enuring this
occurs. All information such as incidents, incident investigations and SHE QN’ relevant to
the area/process has to be reviewed.

4. Control the Risk

4.1. The Control treatments for the control of a risk describes, in order of preference, the
measures that may need to be used to control a hazard. The hierarchy of control treatment
is:
1. Elimination of the hazard - this means 'designing out' hazards when planning new
materials, equipment, and work systems.

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Standard Operating Procedure
Title: Environmental, Health and Safety – Risk Management
___________________________________________________________________________________________________________

6. Appendix 1 - Hazards and EHS Control Strategies

6.1. Introduction
This is a summary of the potential hazards that may be present within the Manufacturing
operations, and the recommended EHS control strategies that shall be considered to control
the hazards.
Note: There is a requirement to adequately consult with personnel working in that area when
changes to the workplace are being considered.

6.2. Typical Process Hazards and their Control Strategies

Hazards Control Strategy

MATERIALS
Toxic material
Corrosive material
Flammable material
Combustible material
Assessment of the material prior to using it on site.
Handle materials in ventilated area or use local exhaust ventilation.
Materials only handled by adequately trained personnel.
Provision of material safety data sheets for all materials.
Materials are correctly labelled.
Store materials in designated & secure safe location.
Wear suitable PPE when handling the material.
Assessment of the material prior to using it on site.
Materials only handled by adequately trained personnel.
Wear suitable PPE when handling the material.
Provision of material safety data sheets for all materials.
Materials are correctly labelled.
Store in suitable containers away from reactive materials.
Store materials in designated & secure safe location.
Assessment of the material prior to using it on site.
Restrict volume stored in depot to licence limits.
Store materials in designated & secure safe location.
Only use flammable cleaning agents in areas where naked flames are
controlled and shielded.
All ignition sources, such as sparks from grinders, should be a safe distance
from material.
Materials only handled by adequately trained personnel.
Wear suitable PPE when handling the material.
Provision of material safety data sheets for all materials.
Materials are correctly labelled.
All ignition sources, such as sparks from grinders, should be a safe distance
from material.
Good housekeeping should prevent combustible material for being put in the
wrong place.

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